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PROPOSAL:

Execute Contract to Cost-Share the Evaluation of Transient Emissions from On-Board Reformers

SYNOPSIS:

Major auto manufacturers are developing proton exchange membrane fuel cell vehicles with on-board reformers as an option. Emissions from these reformers during startup and acceleration modes could be potentially significant, and could affect fuel cell performance. Control of these emissions are needed to enable vehicles with reformers to meet near zero-emission standards. ARCADIS has proposed to evaluate the transient emissions of the on-board reformers built by Hydrogen Burner Technology (HBT) and Epyx, and also develop emission controls for the HBT reformer. AQMD funding shall not exceed $105,000, and will be used to fund the clean fuels portion of the project. Total project cost is anticipated to be $511,000, with co-funding by DOE ($406,000).

COMMITTEE:

Technology, June 25, 1999, Recommended for Approval

RECOMMENDED ACTION:

Authorize the Chairman to execute a contract with ARCADIS Geraghty & Miller to cost-share the evaluation of emissions from on-board reformers, and develop emission controls, in an amount not to exceed $105,000 from the Clean Fuels Program Fund.

Barry R. Wallerstein, D.Env.
Executive Officer

Background

The major auto-makers are planning to introduce fuel cell vehicles into this Basin within the next few years. These fuel cell vehicles are expected to be fueled by gasoline, methanol, ethanol or direct hydrogen. Vehicles fueled by gasoline, methanol and ethanol will require on-board reformers to convert the hydrocarbon fuel into the hydrogen necessary to operate the proton exchange membrane fuel cell (PEMFC), the technology widely expected to power these new vehicles.

PEMFC vehicles powered by direct hydrogen will have zero emissions and the highest system efficiencies. Emissions from vehicles using on-board reformers and fueled by gasoline, methanol or ethanol are expected to be near-zero during steady-state or normal operation. However, given that fuel reforming involves some auxiliary combustion processes, emissions may not be zero during startup and rapid acceleration. These emissions may require additional controls to qualify the vehicles under the ARB’s super-ULEV standards.

Partial oxidation reformers are among the leading technologies for onboard reforming. Though not as efficient as steam reformers, partial oxidation reformers have the potential to be less expensive. Partial oxidation reformers convert hydrocarbon fuels (such as natural gas, methanol, ethanol, gasoline) into carbon monoxide and hydrogen. Carbon monoxide is poisonous to the PEMFC fuel cell, and is therefore removed. Contaminant-free hydrogen is then delivered to the fuel cell to power its operation.

There are currently two types of partial oxidation based on-board reformers under development: thermal-based, and catalyst-based. HBT manufactures thermal partial oxidation reformers, while Epyx, a subsidiary of Arthur D. Little, manufactures catalytic partial oxidation reformers.

Proposal

ARCADIS will develop and implement a test program to identify sampling and analytical techniques to characterize and measure the range of emissions from HBT and Epyx reformers using several clean hydrocarbon fuels, including methanol, ethanol and natural gas. Pollutants emitted are expected to be NOx, CO and unburned non-methane organic gases (NMOG). NOx emissions are expected to be low, and CO emissions are cleaned downstream of the reformer. However, NMOG emissions during startup and acceleration modes may be significant, and despite their short duration, can be substantially higher than those during the remaining, much longer, portion of the driving cycle.

ARCADIS, in conjunction with HBT, will then test an anode catalytic burner for the HBT reformer. The burner would be tested under different configurations to capture and destroy residual NMOG emissions. The feasibility, effectiveness and economics of incorporating different catalysts in the anode gas burner to control NMOG emissions will also be determined, along-with the minimum catalyst temperature needed to destroy the NMOG emissions, the optimum physical placement of the catalyst, the control of undesirable by-products, and methods to enhance catalyst durability. In addition, catalyst size and metal loading will be optimized to minimize system cost.

The above program will be conducted on four fuels - namely, gasoline, methanol, ethanol, and natural gas. AQMD funds will be used to test and control emissions from clean fuels only, namely methanol, ethanol and natural gas.

Benefits to AQMD

The proposed project is included in the November 1998 update of the Technology Advancement Plan under Project 98M3-2, Optimization of Fuel Cell Systems for Integration into Mobile Applications. The AQMP relies on the expedited implementation of advanced technologies and fuel cell vehicles in Southern California to achieve air quality standards. Fuel cells are a promising technology for achieving zero to near-zero emissions in motor vehicles. Positive findings from this project would facilitate the advancement of partial oxidation technology used in fuel cell vehicles. The anode catalytic burner technology could potentially provide substantial emissions reductions of NMOG emissions from these reformers during startup and transient conditions, thereby enabling fuel cell vehicles with such reformers to meet stringent low-emission levels.

Sole Source Justification

Section VIII.B.2 of the Procurement Policy and Procedure identifies four major provisions under which a sole source award may be justified. This request for a sole source award is made under provisions B.2.c. (2): the project involves the use of proprietary technology; B.2.c.(3) the contractor has ownership of key assets required for project performance; and B.2.d (1) other circumstances, including projects involving cost-sharing by multiple sponsors. It is in the best interest of the AQMD to cosponsor the proposed project, whose participants include ARCADIS, Hydrogen Burner Technology, Epyx, Department of Energy and significant co-funding.

ARCADIS is a leading company for alternative fuel demonstration projects in California, and has actively participated in several state and locally sponsored environmental programs. It recently completed an evaluation of process simulations of various configurations of fuel cell reformer technologies for the Air Resources Board. ARCADIS has also extensive experience in sampling emissions from industrial and vehicle sources, including evaluation of emissions from the HBT stationary off-board reformer. This experience and capabilities are essential to successfully completing the proposed projects.

HBT is a leading developer of thermal-based partial oxidation reformers. HBT holds several patents on the technology and is already marketing commercial size stationary off-board hydrogen generation systems based on this technology. Thus, the key asset that HBT owns is the proprietary knowledge and unrestricted access to its own distinctive on-board reformer technology. Its facility in Long Beach is equipped to design, engineer, fabricate and assemble these reformers, and to conduct extensive emission testing on a variety of fuels.

Epyx, a subsidiary of Arthur D. Little, has successfully developed a catalyst based partial reformer that operates at steady state. It is currently developing two 50 kW fuel processor subsystems for transportation, with the goal of meeting stringent DOE 2000 targets for efficiency, emissions, start-up time, weights and volumes. The proposed AQMD funded project will support the testing of emissions from these reformers using clean fuels.

DOE is funding research and development on fuel cells and fuel under its Partnership for a New Generation of Vehicles (PNGV) program. The proposed project is an outcome of a recent competitive solicitation issued by DOE. ARCADIS secured an award for $185,000 from DOE to complete the HBT reformer evaluation, and develop emission controls for it. The evaluation of the Epyx reformer is currently under consideration by DOE. Initiation of the Epyx reformer portion of the proposed project will be contingent upon an award for an additional amount of at least $200,000 from DOE or from another source.

Resources Impacts

The total amount of AQMD funding for the proposed $511,000 project will not exceed $105,000. The balance of the co-funding, $406,000, will be provided by the DOE.

Sufficient funds are available from the Clean Fuels Fund, established as a special revenue fund resulting from the state-mandated Clean Fuels Program. The Clean Fuels Program, under Health and Safety Code 40448.5 and 40512 and Vehicle Code 9250.11, establishes mechanisms to collect revenues from mobile sources to support projects to increase the utilization of clean fuels, including the development of the necessary advanced enabling technologies. Funds collected from motor vehicles are restricted, by statute, to be used for projects and program activities related to mobile sources that support the objectives of the Clean Fuels Program. This project is a proper use of these funds because the proposed technology, if successful, will facilitate the introduction of low emission fuel cell vehicles with on-board reformers.

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